Shipping container

ABSTRACT

A container for stackable articles includes a base assembly, a plurality of side assemblies, a top assembly, and a plurality of shelf assemblies. The base assembly, side assemblies, and top assembly are preferably constructed of a multiple layer, corrugated laminate, and are attachable to one another, defining an interior storage space. Each shelf assembly includes a plurality of shelf support members with a plurality of bearing portions adjacent and integral to each shelf support member. A plurality of shelf members are provided, wherein each shelf member is fixed about a respective bearing portion at each end of the shelf assembly. The shelf assemblies are secured to the sidewall assemblies, and positioned in the storage space to engage manufactured articles, for example sunroofs, positioned therein.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 60/812,906 having a filing date of Jun. 12, 2006.

TECHNICAL FIELD

The present invention relates generally to shipping and storage containers, and more particularly to a novel shelf assembly within such a container.

BACKGROUND OF THE INVENTION

Many different shipping container designs have been developed over the years, some having relatively elaborate interior shelf and article-positioning systems. One such example is found in U.S. Pat. No. 5,667,090 to Langham et al., which discloses an octagonal shipping container for shipping stackable manufactured articles. The Langham container includes a plurality of attached slotted wall panels defining an interior storage cavity. Langham further discloses a plurality of shelf arms which project through the slots to engage goods positioned in the storage cavity. Langham represents one method of storing and shipping stackable manufactured articles, in particular steering wheels. However, there is always room for improvement. For instance, the Langham container must be laid on its side upon a support fixture for loading, necessarily increasing the time and effort required to place articles into, or remove them from, the container. Further, Langham requires a separable fastener to secure the sides of the container.

Co-owned U.S. Pat. No. 6,832,562, herein incorporated by reference in its entirety, describes a shipping container for stackable articles. The container includes a base assembly, a plurality of side assemblies, a top assembly, and a plurality of shelf assemblies. The base assembly, side assemblies, and top assembly are preferably constructed of a multiple layer, corrugated laminate, and are attachable to one another, defining an interior storage space. Each shelf assembly includes a plurality of shelf support blocks with a plurality of face sections distributed along a length, and a shelf flap. The shelf assemblies are secured to the sidewall assemblies, and positioned in the storage space to engage manufactured articles, for example sunroofs, positioned therein. The design of this container provided certain advantages including the elimination of wood augmentation in the container, thereby meeting customer requirements that mandated the elimination of wood due to infestation concerns. Furthermore, the likelihood of damage to articles shipped within this container was substantially reduced due to the enhanced strength of the shelf assemblies. The load time of sunroofs, for example, was also substantially reduced given the prefabricated shelf assemblies within this container. Nevertheless, continued goals include providing even stronger shelf assemblies, and reducing the manufacturing complexity associated with shipping containers.

It is thus desirable to construct a container for stackable goods that can be easily assembled and loaded, yet is strong and durable. The present invention addresses one or more of the limitations or problems associated with the related art.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides a container for shipping and storing manufactured articles. The container includes a container body with a base assembly and a plurality of walls. Each of the walls includes a lower edge attached to the base assembly and at least one lateral edge joined to an adjacent wall panel. At least one shelf assembly, and preferably a plurality of shelf assemblies, is also provided which are secured to the wall assemblies and protrude into an interior of the container body. A first shelf assembly includes a first shelf support member and a second shelf support member for structural support of the shelf assembly. Each shelf support member includes at least a first block portion or shelf bearing portion, and a second block portion or shelf bearing portion integral thereto, wherein the first and second block portions together define a first recessed slot or notch therebetween. At least one shelf member extends between the first and second shelf support members, thereby forming a shelf extending substantially across the interior of the container. A preferred embodiment includes two shelf assemblies containing more than two block portions, thereby accommodating a plurality of shelf members.

Stated another way, the present invention includes a container including at least one shelf assembly and preferably a plurality of shelf assemblies. Each shelf assembly includes a first shelf support member containing a first plurality of adjacent and integral block portions and a second shelf support member containing a second plurality of adjacent and integral block portions. Each one of the second plurality of block portions corresponds to one of the first plurality of block portions. A first plurality of slots is contained within the first shelf support member wherein each slot is defined between two sequential or adjacent block portions of said first plurality of block portions for support of a shelving member described below. A second plurality of slots is contained within the second shelf support member wherein each slot is defined between two sequential or adjacent block portions of said first plurality of block portions for support of a shelving member described below. A first plurality of shelf members is provided wherein each shelf member includes a first tab, a second tab, a third tab, and an aperture, wherein each first tab is fixed within a respective one of the first plurality of slots, each second tab is fixed within a respective one of the second plurality of slots, and each third tab mates with an aperture of an adjacent shelf member.

Other shelf assemblies may be formed in the same manner and employed within the interior of the shipping container. In general, containers formed in accordance with the present invention will preferably contain two shelf assemblies on opposite sides of the shipping container interior.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial exploded view of one embodiment in accordance with the present invention;

FIG. 2 is a partial exploded view of one embodiment in accordance with the present invention;

FIG. 3 is a partial exploded view of one embodiment in accordance with the present invention;

FIG. 4 is an exploded view of the shelf assemblies in accordance with the present invention;

FIG. 5 is an exploded view of the shelf assemblies in conjunction with the wall assemblies;

FIG. 6 is a plan view of a laminate of multiple layers of corrugated material for forming shelf support members in accordance with the present invention.

FIG. 7 is a perspective view of a shelf support member in accordance with the present invention;

FIG. 8 is a plan view of a shelf member in accordance with the present invention;

FIG. 9 is a partial exploded view of one embodiment in accordance with the present invention;

FIG. 10 is a partial exploded view of one embodiment in accordance with the present invention;

FIG. 11 is a partial exploded view of one embodiment in accordance with the present invention;

FIG. 12 is a partial exploded view of one embodiment in accordance with the present invention;

FIG. 13 is an exploded view of one container in accordance with the present invention; and

FIG. 14 is a partial exploded view of one embodiment in accordance with the present invention.

DETAILED DESCRIPTION

FIGS. 1-14 illustrate one embodiment of a container 10 for use in storing, shipping, and protecting any of a variety of substantially flat components or sub-assemblies (for example, sunroofs mountable in automobile assemblies.) In the embodiment disclosed herein, unless otherwise stated, components of the container are formed using known processes from one or more laminated layers of a corrugated material, such as a corrugated board or paper material. However, the use of alternative materials, such as wood, polymers, or metals is also contemplated. In addition, unless otherwise stated, known methods of joining together pieces of corrugated material, such as nailing, gluing or adhesive application, stapling, bump stitching, and other known methods are all contemplated for use in assembling the container and components described herein.

FIG. 1 illustrates a base 12 of the container 10. Base 12 comprises a frame portion 12 a (for example, a corrugated laminate pallet, or a wooden shipping pallet) and a container bottom portion 12 b. Bottom portion 12 b has a body 12 c and a plurality of flaps 12 d formed along edges of body 12 c. Bottom portion 12 b may also be formed from a sheet of corrugated material cut to form flaps 12 d, which are then folded upward and secured to each other as shown to form a tray-like structure. The bottom portion is then nailed, glued, stapled, or otherwise secured to frame portion 12 a.

Referring to FIG. 2, a body portion 14 is positioned and secured within base portion 12. Body portion 14 has a rear wall portion 14 a and a plurality of side flaps 14 b and base flaps 14 c formed along edges of rear wall portion 14 a. Body portion 14 may be formed from a sheet of corrugated material cut to form side flaps 14 b and base flaps 14 c which are then folded as shown and secured to base portion body 12 c and to base portion flaps 12 d.

Referring to FIG. 3, a rear stop portion 16 is secured to rear wall portion 14 a to provide a cushion or shock absorbing member for articles inserted into and stored in container 10. Rear stop portion 16 may also occupy dead space between rear wall portion 14 a and edges of the components stored in the container, thereby aiding in immobilization of the components stored in the container. Rear stop portion 16 may be formed from a sheet of corrugated material cut to size and folded as shown to produce a shock-absorbing wedge 16 a therein. The rear stop portion is then positioned and secured to rear wall portion 14 a of body portion 14. Alternatively, foam or other padding may be secured to rear wall portion 14 a of body portion 14 to provide the desired cushioning effect.

Referring to FIGS. 5-8, a left wall 20 and right wall 22 of the container are provided for supporting the components to be stored and shipped in the container. Walls 20, 22 each include respective wall portions 20 a, 22 a, a plurality of shelf support portions 24 secured to wall portions 20 a, 22 a, and a plurality of shelf portions 18 secured to wall portions 20 a, 22 a and supported by shelf support portions 24.

FIG. 6 is a plan view of a laminate of multiple layers of corrugated material for use in forming shelf support portions 24 of the present invention, shown prior to cutting of the shelf support portions. FIG. 7 is a perspective view showing a laminated shelf support portion 24 of the container 10 of the present invention cut to shape. Referring to FIGS. 6 and 7, shelf support members or portions 24 may be produced by forming a laminate of multiple layers of corrugated material and die-cutting or otherwise cutting the laminate to the achieve the desired profile or shape shown in FIG. 7. For example, using the laminate arrangement of FIG. 6, eight shelf support portions may be cut from a single laminate.

The laminate may be formed to any desired thickness, subject to any process limitations, to provide a desired degree of strength to the shelf support member. As seen in FIGS. 6 and 7, in one embodiment, shelf support portions 24 includes a plurality of bearing portions 24 a, with a slot 24 b formed between adjacent ones of bearing portions 24 a. In the embodiment shown, bearing portions have a saw-tooth configuration or wedge shape which provides a relatively strong base in the region of the bearing portion which is under the greatest mechanical stresses, due to the weight of the part being supported. Slots 24 b are dimensioned (in conjunction with tabs 18 f on shelf portions 18, described in greater detail below) so as to provide an interference fit with tabs 18 f inserted therein, thereby providing additional structural stability to the container.

Referring to FIG. 8, shelf portions 18 are provided which span a distance between adjacent shelf support portions 24, thereby providing substantially continuous support of the stored components along the lengths thereof when they are positioned and secured within the container. Shelf portions 18 may be formed as shown in FIG. 8, wherein one or more sheets of corrugated material are cut to the shape shown an then cut down the center thereof (along line 18 a) to form two shelf members 18.

In one method of assembly of walls 20, 22, shelf portions 18 are folded along folds 18 b and 18 c (FIG. 8), to substantially conform to the profile of bearing portions 24 a (FIGS. 6 and 7) of shelf support portions 24. Successive ones of shelf members 18 are then connected or daisy-chained together by fixing or inserting tab 18 d from one shelf portion 18 into slot or aperture 18 e of an adjacent shelf portion 18, thereby creating a continuous, accordion-like shelf structure. “Fixing” may mean simply inserting the tab or flap 18 d into the corresponding aperture 18 e of the next adjacent shelf member 18. Or, “fixing” may mean to glue or otherwise ensure that flap 18 d is snugly fit within aperture 18 e of the subsequent or adjacent shelf member 18. This shelf structure may be easily positioned to follow the contours defined by shelf support bearing portions 24 a, by bending tabs 18 f out of the plane of the shelf section on which they are formed, and inserting tabs 18 f into corresponding slots 24 b formed or defined between adjacent bearing portions 24 a of shelf support portions 24. Tabs 18 f are formed in positions along shelf portions 18 such that insertion of the tabs into slots 24 b forces the shelf portion structure to bend according to the contours of the shelf support portion. When all of tabs 18 f have been inserted into associated slots 24 b, the tabs are bent back into the plane in which they were originally formed, during which a formed end of each shelf portion 18 wraps over a corresponding surface of a bearing member 24 a of shelf support portion 24. Shelf portions 18 are now supported at each end thereof by a bearing portion 24 a. Shelf support portions 24 may then be positioned along wall portions 20 a, 22 a and glued or otherwise secured to the wall portions.

Other assembly methods or sequences are also contemplated. For example, shelf support portions 24 may be secured to wall portions 20 a, 22 a prior to attachment of shelf portions 18 thereto. When walls 20, 22 are complete, each wall is secured to a corresponding side flap 14 b of body portion 14.

FIG. 14 shows a front 30 of the container. Front 30 comprises a body 30 a and a plurality of flaps 30 b formed along edges of body 30 a. Front 30 may be formed from a sheet of corrugated material cut to form flaps 30 b, which are then folded and secured to each other as shown so as to wrap over edges of walls 20, 22. A shock absorbing positioning member such as rear stop portion or a foam padding, similar to that provided along rear wall 14 a, may be secured to an interior surface of front 30.

FIG. 9 shows a top 32 of the container. Top 32 comprises a body 32 a and a plurality of flaps 32 b formed along edges of body 32 a. Top 32 may be formed from a sheet of corrugated material cut to form flaps 32 b, which are then folded and secured to each other as shown to form a top which may be wrapped over upper edges of walls 20, 22 and body portion 12.

FIGS. 10-13 show various stages in the final assembly of the shipping container 10.

It should be understood that the present description is for illustrative purposes only, and should not be interpreted to limit the scope of the present invention in any way. Thus, those skilled in the art will appreciate that various modifications to the disclosed embodiments might be made without departing from the intended spirit and scope of the present invention, which should be given the full breadth of the claims and any and all equivalents thereof. For example, a preferred embodiment has been illustrated as having four walls, however, the shelf assembly that is an object of the present invention might find application in three sided or many sided containers, or even as a separate stand alone shelf. As discussed above, substantial variations might be made to the number and positioning of shelf assemblies within the container, allowing goods of differing shapes and sizes to be positioned in the same container, for instance, sunroofs for different vehicle models. Further, the presently disclosed shelf assembly could find application in containers designed not for shipping, but for permanent storage or display of manufactured articles. Other objects and features of the present invention will be evident upon an examination of the attached drawing figures and appended claims. 

1. A container for shipping and storing manufactured articles, said container comprising: a container body having a base assembly and a plurality of wall assemblies, wherein each of said plurality of wall assemblies includes a wall panel with a lower edge attached to said base assembly, and at least one lateral edge joined to an adjacent wall assembly; at least one shelf assembly secured to at least one of said wall assemblies and protruding into an interior of said container body, said at least one shelf assembly including a first shelf support member and a second shelf support member for supporting at least one shelf member; a first shelf member comprising a first end and a second end, a first tab at said first end, a second tab at said second end, a first flap, and a first aperture; a first bearing portion and a second bearing portion integral to said first shelf support member for support of said at least one shelf member, said first and second bearing portions defining a first slot, said first tab fixed within said first slot; and a third bearing portion and a fourth bearing portion integral to said second shelf support member for support of said at least one shelf member, said third and fourth bearing portions defining a second slot, said second tab fixed within said second slot.
 2. The container of claim 1 further comprising: a second shelf assembly secured to at least one of said wall assemblies and protruding into an interior of said container body across from said first shelf assembly, said second shelf assembly including a third shelf support member and a fourth shelf support member for supporting said at least one shelf member; a second shelf member comprising a third end corresponding to said first end of said first shelf member, and a fourth end corresponding to said second end of said first shelf member, a third tab at said third end, a fourth tab at said fourth end, a second flap, and a second aperture; a fifth bearing portion and a sixth bearing portion integral to said third shelf support member for support of said first shelf member, said fifth and sixth bearing portions defining a third slot, said third tab fixed within said third slot; and a seventh bearing portion and an eighth bearing portion integral to said fourth shelf support member for support of said second shelf member, said seventh and eighth bearing portions defining a fourth slot, said fourth tab fixed within said fourth slot, wherein said second shelf member is substantially parallel to said first shelf member.
 3. The container of claim 2 further comprising: a third shelf member adjacent to and substantially parallel to said first shelf member, said third shelf member comprising fifth tab at one end, a sixth tab at a second end, and a third aperture; and a fourth shelf member adjacent to and substantially parallel to said second shelf member, said fourth shelf member comprising a seventh tab at one end, an eighth tab at a second end, and a fourth aperture, wherein the first flap of said first shelf member is fixed within the third aperture of said third shelf member and the second flap of said second shelf member is fixed within the fourth aperture of said fourth shelf member.
 4. A shipping container comprising: a first shelf support member comprising a first plurality of adjacent and integral block portions; a second shelf support member comprising a second plurality of adjacent and integral block portions, each one of said second plurality of block portions corresponding to one of said first plurality of block portions; a first plurality of slots, each one of said first plurality of slots defined between two adjacent block portions of said first plurality of block portions; a second plurality of slots, each one of said second plurality of slots defined between two adjacent block portions of said second plurality of block portions; and a first plurality of shelf members, each shelf member comprising a first tab, a second tab, a third tab, and an aperture, wherein each first tab is fixed within one of said first plurality of slots, each second tab is fixed within one of said second plurality of slots, and each third tab mates with an aperture of an adjacent shelf member.
 5. The shipping container of claim 4 wherein said block portions are wedge portions.
 6. The shipping container of claim 4 further comprising: a third shelf support member comprising a third plurality of adjacent and integral block portions; a fourth shelf support member comprising a fourth plurality of adjacent and integral block portions, each one of said fourth plurality of block portions corresponding to one of said third plurality of block portions; a third plurality of slots, each one of said third plurality of slots defined between two adjacent block portions of said third plurality of block portions; a fourth plurality of slots, each one of said fourth plurality of slots defined between two adjacent block portions of said fourth plurality of block portions; and a second plurality of shelf members, each shelf member comprising a first tab, a second tab, a third tab, and an aperture, each one of said shelf members of said second plurality corresponding to a respective one of said first plurality of shelf members, and said second plurality of shelf members in substantial parallel orientation to said first plurality of shelf members, wherein with regard to said second plurality of shelf members, each first tab is fixed within one of said third plurality of slots, each second tab is fixed within one of said fourth plurality of slots, and each third tab mates with an aperture of an adjacent shelf member.
 7. A shipping container comprising: a first shelf support member comprising a first block portion; a second shelf support member comprising a second block portion; a first slot defined adjacent to said first block portion on said first shelf support; a second slot defined adjacent to said second block portion on said second shelf support; and a shelf member comprising a first tab and a second tab, said first tab fixed within said first slot, and said second tab fixed within said second slot, wherein said shelf member is fixed about said first and second block portions.
 8. The shipping container of claim 7 wherein said block portions are wedge portions.
 9. The shipping container of claim 7 further comprising: a plurality of shelf members, and, a first plurality of first tabs wherein each of said first tabs corresponds to a respective shelf member, a second plurality of second tabs wherein each of said second tabs corresponds to a respective shelf member, a third plurality of third tabs wherein each of said third tabs corresponds to a respective shelf member, and a plurality of apertures wherein each of said apertures corresponds to a respective shelf member, a first plurality of adjacent block portions integral to said first shelf support member; a second plurality of adjacent block portions integral to said second shelf support member; a first plurality of slots, each of said first plurality of slots defined between two adjacent block portions of said first plurality of wedge portions; a second plurality of slots, each of said second plurality of slots defined between two adjacent block portions of said second plurality of block portions wherein each first tab is fixed within one of said first plurality of slots, each second tab is fixed within one of said second plurality of slots, and each third tab mates with an aperture of an adjacent shelf member.
 10. A shelf assembly comprising: a first shelf support member comprising a first block portion and a second block portion, said first and second block portions defining a first notch therebetween; a second shelf support member comprising a third block portion and a fourth block portion, said third and fourth block portions defining a second notch therebetween; and at least one shelf member having a first end and a second end, said shelf member comprising a first portion extending along a length of said shelf member, said first portion comprising a first tab at said first end, and a second tab at said second end, wherein said first tab is fixed within said first notch and said second tab is fixed within said second notch, and, said at least one shelf member is fixed about the contours of said second and fourth block portions. 